Process optimization and comparative analysis of EDM and EDD process in machining Al6063/10% SiC metal matrix composites

Abstract

In this work, a comparative investigation of electric discharge machining (EDM) and electric discharge drilling (EDD) hasbeen presented to evaluate the performance measures for machining blind holes in Al6063/10% SiC metal matrix composites(MMCs). The work has been conducted with an aim of optimizing the material removal rate (MRR), tool wear rate (TWR), andsurface roughness (SR). The input parameters chosen for machining are (i) discharged current, (ii) pulse-on time, and (iii) dutyfactor. The Taguchi’s L9 orthogonal array has been applied to design the experiments. The grey relational analysis has also beenused to determine the optimal level of input parameters to achieve better results. Analysis of variances (ANOVA) has beenapplied to perform the statistical analysis of the experimental data. The results have shown that discharge current is the mostinfluencing factor that affects the multiple performance characteristics in both EDM and EDD processes.